Real-time monitoring of force conditions
on a shield cutterhead during tunneling is challenging, leading to delayed
analysis, decision-making, and untimely feedback on the
operational status. To address this challenge, a novel real-time stress analysis method for the cutterhead, which leverages
digital twin technology, is proposed. First, a digital twin framework for real-time stress analysis of the shield cutterhead is established. Finite
element analysis is then performed on the basis of actual working conditions to
determine the stress distribution of the cutterhead under various working
conditions. Second, to improve computational efficiency and real-time performance, open-source software is
employed to extract and process all node data. Based on the extracted stress
data, a stress data model for the cutterhead is developed, and its accuracy and
reliability are validated through comparison with the measured data.
Subsequently, proper orthogonal decomposition method is applied to investigate
the model order reduction techniques for the cutterhead finite element model
based on the developed data model. This order reduction technique significantly
decreases the computational load while maintaining acceptable accuracy,
enabling rapid acquisition and real-time analysis of
the cutterhead′s stress state. The proposed method
facilitates the efficient extraction of cutterhead stress data under different
construction conditions, enabling dynamic monitoring. Finally, the research
findings are integrated into the shield′s digital twin
system, achieving real-time stress analysis and
visualization of the cutterhead. The system can monitor the cutterhead′s stress conditions in real-time based on
the actual working states and provide immediate feedback. The results demonstrate
that the proposed method exhibits high virtual-physical
consistency and reliability in practical applications, providing effective
support for the digital monitoring of shields.
LIAO Jinjun
,
YU Zhongbo
,
JIANG Haihua
,
ZHAO Guisheng
.
Rapid Stress Response Analysis of Shield Cutterhead
Based on Digital Twin Technology
[J]. Tunnel Construction, 2025
, 45(4)
: 844
-851
.
DOI: 10.3973/j.issn.2096-4498.2025.04.017
